Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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CO/002
CORNER STUDS FOR PREFABRICATED BUILDING SYSTEMS
Background of the Invention
Thls invention relates to corner studs for
prefabricated building systems. More particularly,
this invention relates to corner studs that directly
interconnect and align with other structural components
to form complete, structurally sound corners.
The construction industry has attempted to
provide simple economical building systems that can be
used to construct stable habitable strictures in the
shortest possible time using the least possible amount
of construction materials and labor -- while also
attempting to provide those systems with as much
freedom of design as possible. One such known building
system includes generally rectangular structural wall
panels that loin together to form a desired structure.
A disadvantage of such a system, however, is that
direct connections between the vertical edges of
ad,Joining panels cannot be made at corners. This
results in the central alignment planes of the panels
(i.e., the vertical plane cutting across the center of
the panel from the middle of one vertical edge to the
middle of the opposite vertical edge) not meeting where
the panels intersect. Thus, a complete and regular
alignment of the central alignment planes cannot be
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maintained throughout the structure, causing a
disruption in the structure's geometric order. This
can result in nonuniform distribution and transmission
of loads and forces. Moreover, when central alignment
planes do not meet at panel intersections, panel
dimensions cannot be easily regularized (if at all).
thus complicating the on-site assembly process.
Another disadvantage of this building system
is that the rectangular panels cannot be easily used,
if at all, to form structurally sound non-90° corners,
as commonly seen in many architecturally aesthetic
structures. Thus, to form such corners, other
construction methods and materials may hive to be used.
causing a loss of uniformity and homogeneity, while
increasing construction time and costs.
Another known prefabricated building system
includes wall panels that have vertical studs with an
edge that includes two converging sides ending at a
vertex pointed away from the parallel sides of the
stud. While corners formed with such interconnected
wall panels maintain alignment of central alignment
planes. the corners are lncompltte (e. g., not squared).
Thus additional materials, labor. and time are often
required to square the corner. Moreover, this system
also cannot be easily used, if at all, to form
complete, structurally sound non-90° corners.
In view of the foregoing, it would be
desirable to provide a corner stud that readily
maintains alignment of central alignment planes and
that readily interconnects to form complete.
structurally sound corners of various angles.
It would also be desirable to provide such a
corner stud that can be used to form structural wall
panels of a prefabricated building system.
Summary of the Invention
It 1s an object of this invention to provide
a corner stud that readily maintains alignment of
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central alignment planes and that readily interconnects
to form complete. structurally sound corners of various
angles.
It is also an object of this invention to
provide such a corner stud that can be used to form
structural wall, panels of a prefabricated building
system.
In accordance with this invention, a corner
stud is provided that includes two substantially
10 parallel sides spaced a distance apart, each side
having a first end and a second end. The first ends of
the parallel sides are juxtaposed. A third side
connects the two parallel sides at their first ends.
The third side also forms an angle with each of the two
15 parallel sides, neither angle equaling 90°. Corner
studs of the present invention can be fabricated with
different angles to form corners of different angles.
The corner studs also can be fabricated with either a
solid or hollow interior. If fabricated with a hollow
20 interior, studs can include end segments connected to
the second ends of the parallel sides. Studs of the
present invention can be preferably used to form
several types of structural wall panels for use in
prefabricated building systems.
25 Brief Descr;.Dtion q~,the Drawings
The above and other objects and advantages of
the invention will be apparent upon consideration of
the following detailed description, taken in
conk unction with the accompanying drawings, in which
30 like reference characters refer to like parts
throughout. and in which:
FIG. 1 is a plan view of corner connections
between one type of known structural wall panels:
FIC. 2 is a plan view of corner connections
35 between another type of known structural wall panels;
FIG. 3 is a plan view of a corner connection
between the panels of FIG. 2;
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FIG. 4 is a plan view of a preferred
embodiment of a corner stud in accordance with the
present invention;
FIG. 5 is a plan view of another preferred
embodiment of a corner stud in accordance with the
present invention;
FIG. 6 is a plan view of another embodiment
of a corner stud in accordance with the present
invention;
FIGS. 7-9 are plan views of corners formed
with corner studs of the present invention;
FIG. 10 is a plan view of another corner
formed with a corner stud of the present~invention:
FIG. 11 is an isometric view of an exemplary
embodiment of a structural wall panel in accordance
with the present invention:
FIC. 12 is a cross-sectional plan view of the
wall panel of FIG. 11;
FIGS. 13-17 are cross-sectional plan views of
other exemplary embodiments of structural wall panels
in accordance with the present invention:
FIC. 18 is plan view of two studs of FIG. 5
,joined together; and
FIC. 19 is a plan view of an embodiment of a
corner track in accordance with the present invention.
Detailed Descriptlon of the Invention
The present invention provides corner studs
that can be used to form complete, structurally sound
corners of various angles for stable habitable
structures. These corner studs maintain alignment of
central alignment planes and can be preferably used in
the prefabricated building system disclosed in Sucre F
U.S. Patent No, 5.642,594, issued July 1. 1997, which
is incorporated by reference herein in its entirety.
FIG. 1 shows a known building system 100 that
includes generally rectangular structural wall panels,
as described above. Central alignment planes 102, 104,
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and 106 do not meet where wall panels 108, 110, and 112
meet. Instead, central alignment planes 102 and 104
intersect beyond the intersection of the vertical edge
of panel 108 and a side of panel 110, and central
alignment planes 104 and 106 intersect beyond the
intersection of the vertical edge of panel 110 and a
side of panel 112. Accordingly, such a structure is
not considered properly aligned, and the geometric
order of the structure is thus not preserved. This can
complicate panel dimensiorilng and the on-site assembly
process.
fIG. 2 shows another known building
system 200, as also described above, that includes~wall
panels formed with a vertical stud having an edge that
has two converging sides ending at a vertex. While
this system maintains alignment of central alignment
planes, as shown with respect to the intersection of
alignment planes 202 and 204 at the intersection of
wall panels 208 and 210, and the intersection of
aligrunent planes 204 and 206 at the intersection of
wall panels 210 and 212. the corners are Incomplete.
Corner section 301, as shown in FIG. 3, for example,
requires additional materials and labor (and thus
additional costs) to form a complete, structurally
sound corner. Squaring corners formed with such panels
is particularly Important with respect to structural
stability and load bearing capacity in muhi-level
structures .
FIG. 9 shows a preferred embodiment of a
corner stud in accordance with the present invention.
Stud 400 includes parallel sides 414 and 416 and a
third side 418 connecting sides 414 and 416. Side 418
is preferably substantially straight and forms an
angle 420 with side 414 and an angle 422 with side 416.
The sum of angles 420 and 422 preferably equals about
180°. Stud 400 preferably includes end segments 424
and 426, which are preferably substantially
perpendicularly connected to parallel sides 414
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and 416, respectively. Ahernatively, end segments 424
and 426 may be connected to respective sides 414
and 416 non-perpendicularly.
Advantageously, many dimensions of stud 400
(e.g.. lengths and widths of sides 414. 416, and 418
and of~end segments 424 and 426) can be varied relative
to each other, along with the number and configuration
of end segments, without departing from the scope and
spirit of the present invention. For example. FIC. S
10 shows another preferred embodiment of a corner stud in
accordance with the present invention. Stud 500
includes parallel sides 514 and 516, side 518
connecting sides 514 and 516, and end segments 524,
and 526 connected respectively to sides 514 and 516.
15 Stud 500 also preferably includes end segment 52$.
which is preferably connected substantially
perpendicularly to end segment 526. Alternatively, end
segment 528 may be connected to end segment 526
non-perpendicularly.
20 Studs 400 and 500 each have a preferably
hollow interior that can remain hollow or be later
filled in with, for example, insulating or reinforcing
material. Alternatively, corner studs of the present
invention can have a solid interior, as shown in the
25 corner stud embodiment of FIG. 6. Stud 600 has
parallel sides 614 and 616 and sides 618 and 630
connecting respective ends of sides 614 and 616.
Although side 630 is shown as straight and
perpendicularly connected to sides 614 and 616.
30 side 630 alternatively can be neither.
Studs of the present invention are preferably
formed from galvanised metal, stainless steel, solid
wood. solid reinforced PVC, solid special plastics.
waste-plastic composites. cellular fiber plastics.
35 extruded structural components and derivatives, or any
other solid materials, solid reinforced materials or
hollow materials with the structural capacity and
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strength required for the construction of a habitable
structure.
Advantageously, studs of the present
invention can be fabricated to form corners of various
angles. For example, a substantially 90° corner can be
formed with two studs 400, as shown in FIG. 7. Each
stud 400 is fabricated with angle 420 equaling about
45° and angle 422 equaling about 135°. The two
studs 400 are interconnected at sides 418 to form the
corner. Note that central alignment planes 402 and 404
meet at zhe intersection (sides 418) of the two
studs 400. Interconnected sides 418 preferably prevent
relative movement in at least two directions between
the studs and provide load bearing capacity for the
corner.
Corners of other angles also can be easily
formed. A substantially 108° corner (which can be used
to build pentagonal structures) can be Formed with two
studs 400 each having angles 420 equaling about 54° and
angles 422 equaling about 126°. as shown in FIG. 8.
Again, central alignment planes 402 and 404 are in
proper alignment. For building a hexagonal structure,
corners of substantially 120° can be formed with two
studs 400 each fabricated having angles 420 equaling
about 60° and angles 422 equaling about 120°, as shown
in FIG. 9. Stud 400 can be advantageously fabricated
with other values of angles 420 and 422 to form corners
of other angles. Values for angle 420 can preferably
range from about 20° to about 85°. Moreover, stud 400
can interconnect with other types of studs or wall
panels to form corners of still more angles. For
example, FIG. 10 shows stud 400 fabricated with
angle 420 equaling about 45° interconnected with a
stud 1032 to form a substantially 135° corner. In each
of the above examples, the central alignment planes are
properly aligned.
Note that while embodiments of stud 400 were
used in the above examples, embodiments of studs 500
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and 600 also can be used to form corners of various
angles.
Advantageously, studs of the present
invention. can be used to form structural wall panels,
5 such as, for example, those sfmilar to the wall panels
of the prefabricated building system disclosed in the
aforementioned U.S. Patent No. 5,642,594. For example.
FIGS. 11 and 12 show a wall panel 1100 incorporating
stud 400 in accordance with the present invention.
10 Panel 1100 includes upper stud 1134 and lower stud 1136
generally horizontally positioned parallel to each
other. Studs 1134 and 1136 are preferably "u" shaped,
having two parallel sides ,joined perpendicularly along
~ uxtaposed free ends with a third side. Stud 400
15 connects upper and lower studs 1134 and 1136. Upper
and lower studs 1134 and 1136 can both be open-ended,
as shown by upper stud 1134 at open-end 1135, or
closed-ended, as shown by lower stud 1136 at
closed-end 1137. Closed-end 1137 is dimensioned and
20 shaped to receive stud 400.
When necessary, depending on the length of
the panel, one or more stiffener elements 1138 of any
desired configuration may be used as shown. Each
stiffener element 1138 is preferably aligned vertically
25 within the panel between upper and lower studs 1134
and 1136, and preferably generally perpendicular to at
least lower stud 1136.
Stud 400 also preferably can be incorporated
in other types of structural wall panels in accordance
30 with the present invention, such as those shown in
FIGS. 13-17. FIG: 13 shows wall panel 1300 that
includes a vertical stud 1340 at the end of the panel.
Vertical stud 1340 finishes the vertical edge of that
end of panel 1300.
35 FIG. I9 shows a wall panel 1400 that includes
a vertical stud 1440 at the end of the panel having one
or more male connection elements 1442. Male connection
element 1442 is dimensioned and shaped such that the
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distance between its parallel sides is preferably
slightly smaller than the distance between the parallel
sides of upper and lower studs 1334 and 1336. This
allows male connection element 1442 to fit preferably
snugly into studs 1334 and 1336 (e. g.. into panel 1100
at the end opposite stud 400). Male connection
element 1442 preferably can have any other desired
configuration that will fit into an ad~joinlng panel or
stud to provide proper interconnection.
FIC. 15 shows~a wall panel 1500 that includes
a stud 1540 having an edge, as described above, that
has two converging sides ending at a vertex, Wall
panel 1500 is advantageous for forming multiple wall
panel intersections, particularly 4-wall "+"
intersections.
FIGS. 16 and 17 show wall panels 1600
and 1700, respectively, that each include a stud 400 at
each end of the panel. As shown, each stud 400 can
have the same or opposite orientation as the other
stud 400 of the panel.
Note that studs 400 having different
angles 420 and 422, as well as studs 500 and 600 having
different angles 520 and 522, and 620 and 622,
respectively, can be used to construct these wall
panels.
Wall panels 1100, 1300, 1400. 1500, 1600,
and 1700 are preferably hollow, and may therefore be
handled, transported, and installed easily by a single
person. Moreover, these panels permit, when necessary,
the installation of any desired insulation or
acoustical material, and provide flexibility with
respect to placing electrical and plumbing lines and
equipment within the panels.
Panels 1100, 1300, 1400, 1500, 1600, and 1700
can be positioned on either horizontal side, such that,
for example, rather than having side 418 of stud 400
facing southwest, as shown in FIGS. 12-15, the panel
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can be positioned upside down to have side 418 facing
northwest.
Alternatively, wall panels 1100, 1300, 1400,
1500. 160.0, and 1700 can be constructed with stud 400
5 and upper and lower studs 1334 and 1336 formed and
assembled from a one-piece element stud, as similarly
disclosed in U.~S. Patent No. 5.642,594.
Studs of the present invention, and wall
panels incorporating such studs, can be directly and
10 easily attached to each other or to other structural
components by coupling and fixing together side 418 to
either another side 418 or a vertical edge of another
panel or stud. Adjoining studs or panels can be .
welded, screwed, pinned, bolted, glued, or otherwise
15 directly fastened to one another. This advantageously
reduces costs and construction time. Furthermore,
various types of connection elements formed and
appropriately shaped and dimensioned on studs of the
present invention, similar to those disclosed in U.S.
20 Patent No. 5,642.594. also can be used to connect
add oining studs and panels.
Further, third-piece connection elements
alternatively or additionally can be used. For
example, FIG. 18 shows two adj olning studs 500
25 connected together via one or more staple-like
connection elements 1844 that fit into optional
recessed receiving areas 1846 (alternatively, ,just
receiving holes can be provided). Any desired number
of elements 1844 in various arrangements (e. g.,
30 parallel or crossing over to form "X" configurations)
may be used. Connection elements 1844 are angled to
match the corner angle formed by the adjoining studs,
and are preferably shaped and dimensioned for both
outside {as shown) and inside corner fastening.
35 Alternatively or additionally, add oining
studs of the present invention, or add oining wall
panels incorporating such studs, can be positioned and
secured within a single-piece corner track as shown in
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the corner track embodiment of FIG. 19. Corner
track 1900 is dimensioned and shaped to securely
receive a pair of radjoining studs (e.g., studs 600
shown in .phantom) and is angled to match the corner
angle formed by the adjoining sLUds. Corner track 1900
preferably has a generally "u" shaped cross section.
Adjoining studs may be secured with both an upper and
lower track 1900 or, depending upon the circumstances,
just an upper or just a lower track 1900.
Advantageously, studs of the present
invention, and panels incorporating such studs,
interconnect such that the central alignment planes
meet where the vertical edges of adjoining studs or
panels intersect, thus maintaining geometric order
throughout the structure. Interconnections of these
studs and panels therefore create a regularized
structural skeleton that uniformly distributes and
transmits all loads and forces.
Studs of the present invention also can be
used, for example, in "stick-built" structures, and are
thus not limited for use in only prefabricated building
systems.
Thus it is seen that easily aligned and
readily interconnected corner studs are presented. One
skilled in the art will appreciate that the present
invention can be practiced by other than the described
embodiments, which are presented for purposes of
illustration and not of limitation, and the present
invention is limited only by the claims which follow.
